Roof deck assembly

ABSTRACT

A waterproof and weatherproof roof deck assembly comprises a plurality of beams, and a plurality of adjacent waterproof panels that rest on the beams. Each panel has a shoulder on all sides thereof that is adjacent to the shoulder of another adjacent panel to form a joint. A strip of deformable material is disposed onto the adjacent shoulders and compressed against the shoulders by a compressing means that is placed against the material. An urging means forces the compressing means against the deformable material and a suitable sealant is placed into the joint and is subsequently bonded to the sides of the panels to form a waterproof and weatherproof joint.

United States Patent 52/466 X 52/309 X 52/309 X 52/437 X Inventors John 0. Carlson 3,320,107 5/1967 Berg Bradford Woods; 3,3 34,557 8/1967 Fitzgibbon. Jack C. Lawrence; James P. Weldeman, 3382,63? 5/1968 Longinottim h Pittsburgh, allot. Pa. 3,464,176 9/1969 (.1ements............7.,

i969 Primary ExaminerPrice C Faw, Jr Patented g 1971 Allorneys- Oscar B. Brumback and Olin E. Williams Assignee Koppers Company, Inc.

ROOF DECK ASSEMBLY 8 Claims, 7 Drawing Figs.

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PATENTED AUG] 1 197i 3, 599 ,384

ROOF DECK ASSEMBLY BACKGROUND OF THE INVENTION This invention relates to a weatherproof and waterproof structural roof deck assembly and a method of producing the same.

Structural materials, such as reinforced concrete, wood, and metal have been used for roof decks for many years. The term roof deck," as used herein, refers to the supporting base over which waterproofing materials are placed to render the roof decks weatherproof and waterproof. In some instances alternate layers of bitumen materials and felt have been assembled or built up" in the field to provide built-up roofs that are waterproof and weatherproof. Built-up roofs conventionally have three to five plies of saturated felt cemented together with bituminous materials such a coal tar or asphalt. The top layer of the bituminous materials have embedded therein gravel or the like to protect the roof from foot traffic, sun, and wind.

In conjunction with roof decks, insulation materials have been used, such as lightweight aggregates, novel wood fibers, and the like; however, roof decks using these insulation materials still require waterproofing with alternate layers of bitumen materials and felt immediately after their installation to preserve the properties of the insulating materials.

Lately, prefabricated units of roofing components, such as roof deck panels, have been developed. These prefabricated units are desirable in that they are easy to handle, easy to transport, and easy to install at the job location. A major problem, however, relating to prefabricated panels is the necessity for providing waterproof joints between adjacent panels.

PRIOR ART U.S. Pat. No. 3,320,707 provides an assembly for covering a roof deck that comprises metal sheet panels that are adjacently placed upon the roof deck. A series of channels are nailed to the roof deck where the channels have a,bight portion with sidewalls diverging downwardly from the bight portion and outwardly extending flanges secured to the roof deck. The panels comprise an insulating material bonded to a sheet of metal having outwardly turned lips that engage the bight of the channels. When the panels are placed adjacently to a channel, a trough is formed by the lips of the sheet metal into which an elastic pad is placed for sealing the joints therebetween. A metal plate of lesser width than the elastic pad is disposed against the pad and secured thereto by metal screws to provide a sealed joint between adjoining panels.

This assembly is used to cover a roof deck and hence it does not use structural panels; the sheet metal is too thin to sustain foot traffic and construction equipment that is conventionally placed on a roof during its installation. It requires a roof deck. Furthermore, the assembly is not completely waterproof as the passage of the screws through the elastic pad to secure the metal plate at the joint of adjoining panels may provide a point at which leakage may occur, especially if the pad is torn by the threads of the screw. The panels cannot be installed during inclement weather as the insulating material would deteriorate if exposed to rain, snow and the like.

The assembly of this invention, on the other hand, provides panels composed of a material that is waterproof and installable during any kind of weather conditions. Alternate layers of bituminous materials are not necessary. The assembly itself is a roof deck component as it is capable of sustaining the normal loads to which a roof is subjected. It is lightweight, unaffected by water, sun or the like, termite proof, incombustible, and capable of being sawn, drilled and nailed.

SUMMARY OF THE INVENTION In accordance with the invention, a plurality of beams are arranged to support a plurality of waterproof, structural panels. The panels are arranged adjacent to each other where each panel includes a shoulder on all sides thereof that is adjacent to the shoulder of another'adjacent panel to form a joint. The panels are held to the beams by a securing means. A strip of deformable material is, then, disposed onto the adjacent shoulders that substantially covers the adjacent shoulders and the joints between adjacent panels. A compressing means is, then, placed over the material for compressing it against the adjacent shoulders to form a sealed joint between the adjacent panels. An urging means placed along the compressing means urges it against the material. Over the compressing means a suitable sealant is placed into the joints of the adjacent panels and subsequently the sealant is bonded to the sides of the adjacent panels to form a waterproof joint therebetween.

GENERAL DESCRIPTION OF THE DRAWINGS In the drawings:

FIG. 1 is an exploded isometric view of the partially assembled roof deck assembly in accordance with the invention;

FIG. 2 is an isometric ,view of the completely assembled roof deck assembly of FIG. 1;

FIG. 3 is a crosssectional view at III-Ill of FIG. 2;

FIG. 4 is a cross-sectional view at IV-IV of FIG. 2;

FIG. 5 is a cross-sectional view illustrating another embodiment of the present invention.

FIG. 6 is an isometric view of a securing means for use with the panels of FIG. 1; and I FIG. 7 is an isometric view of an urging means for use with the panels of FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS The roof deck assembly of FIG. 1 comprises a pluralityof beams 11, a plurality of panels 13, a plurality of securing means 15, strips of deformable material 17, compressing means 19, urging means 21, and a sealing compound 23 as illustrated in FIG. 2.

The beams 11 are elongated members that comprise a stem portion 11a in FIG. 3 and outwardly directed flanges 11b extending from one end of the stem 11a, generally defining an inverted T. The beams 11 are arranged in a generally parallel spaced-apart relationship in respect of each other and are fastened to steel joists 25 or the like in FIG. 1. Usually the beams 11 are placed on top of the frame of a building for supporting a roof. The present invention contemplates the use of these beams II in conjunction with the panels 13 for use on a flat horizontal roof, or on an inclined roof.

In an alternate embodiment of the present invention, the beams 11 comprise, as illustrated in FIG. 5, a stem portion 11a, outwardly directed flange portions 11b extending from one end of the stem 11a, and a bulb portion at the other end of the stem 11a, generally defining an inverted T. With the beams 11 of either embodiment of the present invention, it is not necessary to provide a subroof in that the beams are preferably composed of a structural steel which is capable of sustaining the loads to which a roof deck assembly is normally subjected. The stem portion 11a of the beams 11 is between adjacent panels 13 where the flanges 11b support the panels 13. Other structural beams of different design, however, may be employed with the present invention.

The panels 13 in FIGS. 3 through 5 have an upper surface 1311, which in association with a plurality of panels defines a roof, and have sidewalls 13b, forming generally a rectangular structure. The sidewalls 13b of the panels 13 have shoulders 27 on all sides of the panels 13. Each shoulder 27 is adjacent to the shoulder 27 of another adjacent panel 13 to form a joint as illustrated in FIG. 1.

The panels 13 are arranged between the beams 11 and are supported by the flanges 11b of the beams. The panels 13 are adjacently placed end to end as illustrated in FIGS. I and 2. When the panels are adjacently placed upon the beams 11,

troughs, generally indicated at 29, are formed by the shoulders I 27 of the adjacent panels. It will be noted, by comparing FIGS.

' 3 and 4, that the width of the shoulders 27 differ to provide a posed of a lightweight concrete having a lightweight aggregate of expanded polymeric particles as described in US. Pat. No.

3,272,765. This material is excellently suited for use in my invention in that it is lightweight, is capable of sustaining loads, is waterproof and weather resistant, and is fire resistant.

The panels 13 are secured to the beams 11 by securing means to prevent the panels from being removed from the beams 11 by wind and the like. Any suitable securing means may be used in accordance with my invention. For instance, a clip 15, as illustrated in FIGS. 3 and 6 comprises an elongate portion 15a that extends over and engages the adjacent shoulders 27 of the adjacent panels 13. Mutual walls 15b are connected to the elongate portion 15a intermediate of the ends thereof and extend downwardly from the elongate portion 15a on each side of the beams 11. Arcuate portions 150 are connected at the ends of the walls 15b intermediate of their ends. The arcuate portions 150 are curved downwardly so that the clip may be easily disposed onto the beam 11; one end of the arcuate portions 150 engage the beams 11. The mutual walls 1512 are resiliently biased toward said beams so that the clip 15 is thereby held to the stem 1 la by friction.

The strip of deformable material 17 is placed coextensively along the shoulders 27 of the panels 13, for providing a sealed joint between adjoining panels. The deformable material 17 may conveniently comprise a continuous strip so as to engage a series of panels as illustrated in FIG. 1. Any material which is resilient and deformable may be used in accordance with the invention, however, the preferable material is a polyurethane foam. The principal purpose of the deformable materials is to prevent the sealant from passing through the joint as hereinafter described.

The compressing means 19 is placed on top of and generally extends over all of the deformable material 17 for compressing the material 17 between the compressing means 19 and shoulders 27. The compressing means 19, illustrated in FIGS. 3, 4, and 5 comprise a flexible plate having generally a W-shaped cross section; however, any shape may be employed in this invention as long as it is capable of suitably compressing all of the deformable material 17. The flexible plate 19 having the W-shaped cross section is capable of forcing the deformable material downwardly against the adjacent shoulders and spreading the deformable material laterally to provide a sealed joint between the adjacent panels when the plate 19 is urged downwardly. The compressing means has a width less than the trough 29 and it extends over the adjacent shoulders 27 of the adjacent panels. The panels, optionally, have a bevel 27c, illustrated in FIGS. 3, 4, and 5 to insure that the compressed material 17 provides a good seal between adjoining panels.

The urging means 21 in FIGS. 3, 4, and 7 comprises a flexible strip originally having a generally inverted V-shaped cross section. The legs 21a of the V are driven into the sidewalls 13b of one panell3 and into the sidewalls 13b of another adjacent panel 13. The apex (21b) then engages and urges the compressing means downwardly against the deformable material 17. Extending from the legs 21a are projection barbs (210) that are firmly embedded into the panels 13 for holding the urging means 21 therein.

The sealant 23 is placed on top of the compressing means 19, flush with the upper surface 130 of the panel. The sealant subsequently forms a bond with the adjoining panels 13, which bond provides excellent waterproofing of the joints therebetween.

The sealants which may be used in accordance with the invention must generally be elastomeric in nature with a minimum extensibility of about 10 percent of the original volume. A wide variety of sealants are available to those skilled in the art and the choice of any particular sealant will depend upon a consideration of the environment to which the novel roof deck assembly is subjected along with the cost of such sealants.

Sealants that may be used in substantially flat roofs having a rise to run ratio of less than one inch to one foot include tar rubber compositions, asphaltic compositions, and ethylene vinyl acetate copolymer wax compositions. The preferable composition for use with the present invention in a substantially flat roof is the tar rubber composition which is composed of a solution of acrylonitrile and butadiene mixed with a coal tar. The physical properties of the tar rubber composition are such that it tends to have cold flow properties, meaning that the compound will run at ambient temperatures if unrestrained. Thus, this kind of sealant requires the use of the deformable strip 17 to prevent the passage of the sealant through the joints between the panels.

In other situations the novel roof deck assembly may be used with inclined roofs having a rise to run ratio greater than 1 inch to 1 foot. The inclined roofs require a sealant that does not possess cold flow properties. Various sealants that may be suitable for this latter application include tar epoxy compositions, asphaltic epoxy compositions, moisture curing silicones, polysulfide compositions such as Thiokol, a trade name, urethane compositions, and bituminous emulsions.

In the manner of constructing the novel roof deck assembly, in accordance with the invention, a plurality of beams or subpurlins 11 are arranged and disposed on the steel joists 25, usually on top of a frame of a building. The panels 13 are arranged on the beams 11 in an adjacent relationship so that the upper surfaces of the panels define a roof wherein the shoulders 27 of the panels are adjacent to the shoulders 27 of another adjacent panel to form the joint. Onto the shoulders 27 the strip of deformable material 17 is placed that substantially covers the adjacent shoulders 27 and covers the joint between the adjacent panel. The deformable material 17 is then compressed by the compressing means 19 to urge the deformable material into contact with the adjacent panels to form a seal that prevents the sealant from passing through the joints between the adjacent panels. The urging means 21 are employed to force the compressing means downwardly against the deformable material. Subsequently thereto, the sealant 23 is placed onto the joints fiush with the upper surfaces 13a of the adjacent panel. Subsequently, the sealant 23 forms a bond with the sides 13b of the adjacent panels to form'the waterproof joint therebetween.

Thus in accordance with the invention, the novel roof waterproof and weatherproof deck assembly is provided which includes several advantages over the prior art. The roof deck assembly units are installable during any kind of weather conditions, they are capable of sustaining loads without a subroof, and they are completely scalable to form the waterproof and weatherproof roof without the necessity of using bituminous materials as heretofore used in the prior art. Thus, the construction of the novel roof deck assembly of the invention is simple and inexpensive.

We claim:

1. A waterproof roof deck assembly comprising:

a. a plurality of beams on top ofa building for supporting a roof;

b. a plurality of adjacent, waterproof panels that are placed on said beams and that are arranged so their upper surfaces define a roof; each panel having a shoulder on all sides thereof that is adjacent to the shoulder of another adjacent panel to form ajoint; a securing means for holding said panels onto said beams; a strip of deformable material disposed onto the adjacent shoulders of adjacent panels that substantially covers the adjacent shoulders and the joints between adjacent panels;

e. a compressing means placed on top of said material for compressing said material against the adjacent shoulders of adjacent panels to form a sealed joint between adjacent panels;

f. an urging means disposed along said compressing means for urging said compressing means against said material; and

g. a sealant having been disposed on top of said means into the joints between the adjacent panels and bonded to the sides of said panels to form a waterproof joint between the adjacent panels.

2. The waterproof roof deck assembly of claim 1 wherein the panels are composed of concrete having a lightweight aggregate of expanded polymeric particles.

3. The waterproof roof deck assembly of claim 1 wherein the strip of deformable material is composed of a foamed polyurethane.

4. The waterproof roof deck assembly of claim 1 wherein the compressing means comprises:

a. a flexible plate having a generally W-shaped cross section that forces said deformable material downwardly against the adjacent shoulders and spreads said deformable material laterally to provide a sealed joint between the adjacent panels when said plate is urged against said material; and

b. said plate having a width so that said plate extends over the adjacent shoulders of adjacent panels.

5. The waterproof roof deck assembly of claim 1 wherein the urging means comprises:

a. a flexible strip having a generally inverted V-shaped cross section in its original form whose legs of the V are driven into the side of one panel and of another adjacent panel and whose apex is subsequently flattened so as to engage and urge said compressing means downwardly against said material; and

b. projecting barbs extending from the legs of said strip so that the legs of said strip are firmly embedded in the sides of said panels.

6. The waterproof roof deck assembly of claim 1 wherein the securing means comprises:

a. an elongate portion that extends over and engages the adjacent shoulders of the adjacent panels;

b. mutual walls that are intermediate of the ends of said elongate portion and that extend downwardly of the elongate portion on each side of said beams; said mutual walls being resiliently biased toward said beams; and

c. arcuate portions at the ends of said walls being intermediately connected thereto and being curved downwardly where one end of each arcuate portion engages said beams whereby said panels are frictionally held to said beams.

7. A process for constructing a roof deck assembly from panels composed of lightweight concrete containing an aggregate of expanded polymeric particles where each panel has a shoulder on all sides thereof comprising:

a. disposing a plurality of beams on top of a building for support of a roof;

b. arranging on said beams a plurality of said panels and forming troughs between said panels by arranging said panels in an adjacent relationship to each other so that the shoulder of one panel is adjacent to the shoulder of another adjacent panel;

c. securing said panels to said beams;

d. disposing a deformable material into said troughs and substantially covering the adjacent shoulders of the adjacent panels with said deformable material;

e. compressing said deformable material in said troughs into a snug engagement with the adjacent shoulders of the adjacent panels;

f. disposing a sealant into said troughs over said compressed deformable material; and

g. bonding said sealant to the sides of said trough of the adjacent panels to render said troughs waterproof.

8. A waterproof roof deck assembly supported upon a plurality of beams comprising:

a. a plurality of panels composed of lightweight concrete containing an aggregate of expanded polymeric particles; each of said panels having a shoulder on all sides thereof; said panels being arranged on said beams in an adjacent relationship to each other so that the shoulder of one panel is adjacent to the shoulder of another adjacent panel to form a trough between the adjacent panels;

b. a deformable material disposed in said troughs and substantially covering the adjacent shoulders of the adjacent panels; j

c. a means for compressing said deformable material in said troughs into a snug engagement with the adjacent shoulders of the adjacent panels;

d. a sealant disposed in said troughs and over said compressed deformable material; said sealant being bonded to the sides of said trough of the adjacent panels to render said troughs waterproof. 

2. The waterproof roof deck assembly of claim 1 wherein the panels are composed of concrete having a lightweight aggregate of expanded polymeric particles.
 3. The waterproof roof deck assembly of claim 1 wherein the strip of deformable material is composed of a foamed polyurethane.
 4. The waterproof roof deck assembly of claim 1 wherein the compressing means comprises: a. a flexible plate having a generally W-shaped cross section that forces said deformable material downwardly against the adjacent shoulders and spreads said deformable material laterally to provide a sealed joint between the adjacent panels when said plate is urged against said material; and b. said plate having a width so that said plate extends over the adjacent shoulders of adjacent panels.
 5. The waterproof roof deck assembly of claim 1 wherein the urging means comprises: a. a flexible strip having a generally inverted V-shaped cross section in its original form whose legs of the V are driven into the side of one panel and of another adjacent panel and whose apex is subsequently flattened so as to engage and urge said compressing means downwardly against said material; and b. projecting barbs extending from the legs of said strip so that the legs of said strip are firmly embedded in the sides of said panels.
 6. The waterproof roof deck assembly of claim 1 wherein the securing means comprises: a. an elongate portion that extends over and engages the adjacent shoulders of the adjacent panels; b. mutual walls that are intermediate of the ends of said elongate portion and that extend downwardly of the elongate portion on each side of said beams; said mutual Walls being resiliently biased toward said beams; and c. arcuate portions at the ends of said walls being intermediately connected thereto and being curved downwardly where one end of each arcuate portion engages said beams whereby said panels are frictionally held to said beams.
 7. A process for constructing a roof deck assembly from panels composed of lightweight concrete containing an aggregate of expanded polymeric particles where each panel has a shoulder on all sides thereof comprising: a. disposing a plurality of beams on top of a building for support of a roof; b. arranging on said beams a plurality of said panels and forming troughs between said panels by arranging said panels in an adjacent relationship to each other so that the shoulder of one panel is adjacent to the shoulder of another adjacent panel; c. securing said panels to said beams; d. disposing a deformable material into said troughs and substantially covering the adjacent shoulders of the adjacent panels with said deformable material; e. compressing said deformable material in said troughs into a snug engagement with the adjacent shoulders of the adjacent panels; f. disposing a sealant into said troughs over said compressed deformable material; and g. bonding said sealant to the sides of said trough of the adjacent panels to render said troughs waterproof.
 8. A waterproof roof deck assembly supported upon a plurality of beams comprising: a. a plurality of panels composed of lightweight concrete containing an aggregate of expanded polymeric particles; each of said panels having a shoulder on all sides thereof; said panels being arranged on said beams in an adjacent relationship to each other so that the shoulder of one panel is adjacent to the shoulder of another adjacent panel to form a trough between the adjacent panels; b. a deformable material disposed in said troughs and substantially covering the adjacent shoulders of the adjacent panels; c. a means for compressing said deformable material in said troughs into a snug engagement with the adjacent shoulders of the adjacent panels; d. a sealant disposed in said troughs and over said compressed deformable material; said sealant being bonded to the sides of said trough of the adjacent panels to render said troughs waterproof. 